Microfiber yarn rotary buffing pad

ABSTRACT

A microfiber yarn is provided for cleaning, polishing, and buffing a target surface. A buffing pad for auto detailing is provided that may be attached to a rotary drive tool that has a microfiber buffing surface, where the microfiber is a yarn, as opposed to a weave. Embodiments of the buffing pad operate to clean and polish a substrate such as a vehicle and ideally return the same to the original look and feel in a fast and efficient manner, while providing high quality finishes with less frequent pad changes.

FIELD OF THE INVENTION

The present invention in general relates to surface cleaning, finishing,and sealing and in particular, to a buffing and polishing article thatuses intimate contact between the buffing and polishing article toclean, finish, and seal a target surface.

BACKGROUND OF THE INVENTION

Historically, debris is cleaned from a surface through the applicationof mechanical abrasive force, chemical displacement, or combinationthereof. While rubbing a target surface with conventional cleaningarticle often is adequate to remove debris electrostatically adhered toa target substrate, many types of debris are resinous or oily therebymaking removal by simply imparting mechanical forces to the debrisdifficult. In such instances, it is routine to include a buffing waxthat serves to focus mechanical energy input to the debris particulate,while surfactants serve to solubilize debris. Unfortunately, resort towaxes and surfactants, each create difficulties that tend to createswirls of wax in the target surface and over time visibly damage thetarget surface, while surfactants are slow to lift debris and tend toleave a film on the target surface that promotes redeposition of debris.

Most American automobiles are factory painted with several layers ofcolored and clear paint or paint-like coatings that together produce abeautiful luster and a smooth feel to the touch, the luster and smoothfeel serving to enhance the value of the car in the eyes of the owner.Over time, the painted/coated surface becomes damaged though by theforces of nature: UV radiation from the sun damages the upper surface ofthe coat causing it to feel rough; air causes the paint to oxidize andlose shine; wind-borne dust produces nicks and scratches in the surface;and dust and grease can become embedded in the surface, as well as,paint overspray and industrial fallout such as rail dust. These agentsact together to dull the look and roughen the feel.

The cleaning of a vehicle exterior surface inclusive of windows, trim,and painted surfaces are exemplary of target surfaces of high value thatare exposed to considerable buildup of grime and debris. A vehiclesurface is also highly prone to diminished visual appearance throughrepeated conventional cleaning. In order to address the above-notedlimitations associated with target surface cleaning with a sponge orcloth, alone or with abrasives, surfactants, or combination thereof.

Many polishing products already appear on the market. These productsfall into three general categories of a liquid or semi-solid polishingpaste, clay polishing erasers, and a polishing towel and pad asdescribed in Taiwan Patent 1247801 and U.S. Pat. No. 7,867,967. Theliquid compounds are messy to use and are time-consuming to apply. Theclay eraser and polishing pads are labor intensive to use.

The cleaning of a vehicle exterior surface inclusive of windows, trim,and painted surfaces are exemplary of target surfaces of high value thatare exposed to considerable buildup of grime and debris. A vehiclesurface is also highly prone to diminished visual appearance throughrepeated conventional cleaning. Traditionally, rotary buffing pads havebeen formed of wool. Wool buffing pads are prone to forming clumps offiber matted with buffing compounds.

Microfiber is a synthetic fiber finer than one denier or decitex/thread.The most common types of microfibers are made from polyesters,polyamides (e.g., nylon, Kevlar, Nomex, trogamide), or a conjugation ofpolyester, polyamide, and polypropylene (Prolen). Microfiber is used tomake mats, knits, and weaves for apparel, upholstery, industrialfilters, and cleaning products. The shape, size, and combinations ofsynthetic fibers are selected for specific characteristics, includingsoftness, toughness, absorption, water repellency, electrostatics, andfiltering capabilities.

In cleaning products, microfiber can be 100% polyester, or a blend ofpolyester and polyamide (nylon). Microfiber can be both a woven productor a nonwoven product, the latter most often used in limited use ordisposable cloths. In the highest-quality fabrics for cleaningapplications, the fiber is split during the manufacturing process toproduce multi-stranded fibers. A cross section of the split microfiberfabric under high magnification would look like an asterisk. The splitfibers and the size of the individual filaments working in conjunctionwith the spaces between them make the cloths more effective than otherfabrics for cleaning purposes. The structure traps and retains the dirtand also absorbs liquids, and unlike cotton, microfiber leaves no lint.

While there have been many advances in materials for cleaning,polishing, and buffing there is an existing need for longer life buffingproducts that are resistant to pilling that leads to swirling of buffingcompound or other irregularities in the buff, as well as the retentionof more buffing wax.

SUMMARY OF THE INVENTION

A surface polishing pad includes a series of microfibers formed as ayarn cut to form fibers with free ends and form a circular disc with thefree ends projecting outward to form a polishing surface. A backing isformed from the yarn.

A process of buffing a vehicle outer surface includes rotating a buffingpad at a speed of between 5 and 1000 rotations per minute (rpm)non-orbitally around an axis, where the buffing surface is formed of amicrofiber yarn, and contacting the buffing pad with the vehicle outersurface.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter that is regarded as the invention is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other objects, features, andadvantages of the invention are apparent from the following detaileddescription taken in conjunction with the accompanying drawings inwhich:

FIG. 1 is a perspective photographic view of an inventive microfiberbuffing showing the buffing surface;

FIG. 2A is a perspective photographic view showing the attachment sideof a buffing wheel fitted with the microfiber buffing pad of FIG. 1;

FIGS. 2B and 2C are cross sectional view of inventive buffing pads;

FIG. 3 is a close up view of the microfiber fibers that make up themicrofiber buffing pad of FIG. 1;

FIG. 4 is a photographic view of the tufting of the microfiber used inthe microfiber buffing pad of FIG. 1; and

FIG. 5 is magnified photographic view of the microfiber yarn used in themicrofiber buffing pad of FIG. 1.

DESCRIPTION OF THE INVENTION

The present invention has utility as an article for cleaning, polishing,and buffing a target surface. A buffing pad for auto detailing isprovided that may be attached to a rotary drive tool that has amicrofiber buffing surface, where the microfiber is a yarn as opposed toa weave.

The present invention operates to clean, polish, and buff a substratesuch as a vehicle and ideally return the same to the original look andfeel in a fast and efficient manner, while providing high qualityfinishes with less frequent pad changes.

Without intending to be bound to a particular theory, an inventivemicrofiber yarn, which is formed from long continuous lengths ofinterlocked microfibers, is resistant to pilling that leads to scratchesor irregularities in the buff, and retention of more buffing wax. Themicrofiber yarn is also more resilient to wear than traditional wovenmicrofiber.

It is to be understood that in instances where a range of values areprovided that the range is intended to encompass not only the end pointvalues of the range but also intermediate values of the range asexplicitly being included within the range and varying by the lastsignificant figure of the range. By way of example, a recited range offrom 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4.

Referring now to the figures a buffing pad is shown generally at 10 withthe microfiber yarn application surface. The buffing surface 11 hasintermixed dark and light colored tufts formed from microfiber yarn forvisual clarity. The buffing surface 11 has a rounded edge along thecircumference of the pad 10, and the density and dispersion of the blueand white tufts is maintained along the rounded edge.

As shown in FIG. 2A, in opposition to the ends of the fibers thatterminate in the buffing surface 11 is a backing 12. It is appreciatedthat the backing 12 is readily formed as a woven mat as shown or is anonwoven mass. The backing 12 has a coating 14. The coating 14 serves tostabilize fibers in a relative position in the backing 12 and alsoserves to increase the rigidity relative an embodiment lacking such acoating 14. A coating 14 is illustratively formed from a hot meltthermoplastic, a latex, a thermoset resin such as an epoxy, a polyurea,or a polyurethane. As best seen with respect to FIGS. 2A-C, a contactplate 16 fitted to the backing 12. The contact plate 16 is adapted tojoin to a buffing tool mount. In a specific inventive embodiment, thecoating 14 is applied to create a concave edge as shown in FIGS. 2A and2B. The typical extent of a concave edge relative to a planar backingcenter is between 0.3 and 1 centimeter (cm). In still other inventiveembodiments, the coating 14′ is applied to create a lip protrudingaround a central disc, the lip then curves backwards as shown in FIG.2C. The typical extent of lip protrusion towards that surface 11 isbetween 0 and 0.3 cm. The inventive pad is adapted to be connected to anon-orbital rotary tool head illustratively including a drill chuck. Acentral hole is conventionally used to receive the shaft of a threadedfastener that is complementary to threads in the tool head.

FIG. 3 is a close up view of the microfiber fibers showing the yarn ofthe dark and light tufts that make up the microfiber buffing surface 11.

FIG. 4 shows the tufting of the microfiber yarn used in the microfiberbuffing surface which greatly increases the surface area of the tip of atuft with the individual microfibers.

FIG. 5 is magnified view of the microfiber yarn used in the microfiberbuffing surface 11.

A process of buffing a vehicle outer surface with an embodiment of theinventive buffing surface 10 includes rotating a buffing pad around anaxis, where the buffing surface 10 is formed of a microfiber yarn at aspeed of between 5 and 1000 rotations per minute (rpm), and contactingthe buffing pad with the vehicle outer surface. A buffing compound maybe applied to the buffing surface or to a target surface of the vehicleprior to contacting the buffing surface to the target surface. In aspecific embodiment the rotating occurs without orbital rotation.

The present invention is further detailed with resort to the followingnon-limiting examples.

EXAMPLES Example 1

An inventive buffing pad of FIG. 2A is mounted to a 12 Amp Corded 7 inchvariable speed polisher with a hook and loop backing pad. The polisheris operated at 30 rpm with a conventional automotive buffing compound onone third of flat panel painted with automotive paint to simulate avehicle exterior. The inventive pad retained the original texture after4 hours of buffing.

COMPARATIVE EXAMPLES

The process of Example 1 is repeated with a conventional wool buffingpad (Comparative Example A) and a conventional microfiber woven(non-tufted) buffing pad. The wool buffing pad was clogged with wax andslick to the touch after 5 minutes of buffing.

The foregoing description is illustrative of particular embodiments ofthe invention, but is not meant to be a limitation upon the practicethereof. The following claims, including all equivalents thereof, areintended to define the scope of the invention.

1. A surface polishing pad comprising: a series of microfibers formed asa yarn cut to form fibers with free ends; said fibers formed a circulardisc with the free ends projecting outward to form a polishing surface;and a backing formed from said yarn.
 2. The article of claim 1 furthercomprising a mounting plate adapted to couple to a rotary device.
 3. Thearticle of claim 1 wherein said backing is a woven mat.
 4. The articleof claim 1 further comprising a coating retaining said backing apredefined shape.
 5. The article of claim 1 wherein said coating is ahot melt thermoplastic, a latex, or a thermoset resin.
 6. The article ofclaim 3 wherein the predefined shape has convex edge along thecircumference of the circular shape.
 7. The article of claim 6 whereinthe convex edge extends relative to a planar backing center between 0.3and 1 centimeter (cm).
 8. The article of claim 3 wherein the predefinedshape is a lip protruding toward the polishing surface around a centralplanar disc, the protruding lip then curving backwards.
 9. The articleof claim 8 wherein the lip extends protrudes relative to a planarbacking center between 0 and 0.3 cm.
 10. The article of claim 1 whereinsaid series of microfibers formed as a yarn comprise at least two colorsof tufts.
 11. A process of buffing a vehicle outer surface comprising:rotating a buffing pad of claim 1 non-orbitally around an axis at aspeed of between 5 and 1000 rotations per minute; and contacting saidbuffing surface with the vehicle outer surface.
 12. The process of claim11 further comprising applying a buffing compound to said buffing pad.